The electric arc furnace (EAF) is a critical steelmaking facility that melts the scrap by the heat produced from electric arc and burners. Simulation and optimization of EAF scrap melting are of great interest to the steel industry, which helps to improve product quality and production efficiency. However, the relevant computational fluid dynamics (CFD) modeling of this process has not been reported so far. The present study established a three-dimensional (3D) integrated CFD model to simulate the scrap melting process in the alternating current (AC) EAF. The scrap melting model was developed to simulate the dynamic scrap melting and collapse based on the dual-cell approach and the stack approach. The electric arc model and the coherent jet model were introduced and integrated with the scrap melting model to estimate the electrical and chemical energy inputs need for melting. The CFD-compatible Monte Carlo method and electrode regulation strategy were developed respectively to predict the arc radiative heat dissipation and track the instant electrode movement. The experiments for the scrap melting by both electric arc and coherent jet burner were designed and implemented in the industry-scale NLMK 150-ton EAF for the model validation. The proposed model was applied to simulate the scrap melting process under the NLMK EAF typical run, and the scrap melting behavior, the electric arc performance, and the burner performance were evaluated and discussed based on the simulation results.

电弧炉 (EAF) 是一个关键的炼钢设施，通过电弧和燃烧器产生的热量来熔化废钢。电弧炉废钢熔炼的模拟和优化对钢铁行业非常感兴趣，这有助于提高产品质量和生产效率。然而，迄今为止尚未报道该过程的相关计算流体动力学（CFD）建模。本研究建立了一个三维 (3D) 集成 CFD 模型来模拟交流电 (AC) 电弧炉中的废钢熔化过程。废钢熔化模型是基于双电池法和电堆法开发的，用于模拟动态废钢熔化和塌陷。引入了电弧模型和相干射流模型，并将其与废料熔化模型相结合，以估计熔化所需的电能和化学能输入。分别开发了与 CFD 兼容的 Monte Carlo 方法和电极调节策略，以预测电弧辐射散热并跟踪瞬时电极运动。在工业规模的 NLMK 150 吨电弧炉中设计并实施了电弧和相干喷射燃烧器熔炼废钢的实验，用于模型验证。将所提出的模型应用于模拟NLMK EAF典型运行下的废钢熔化过程，并根据模拟结果对废钢熔化行为、电弧性能和燃烧器性能进行了评估和讨论。分别开发了与 CFD 兼容的 Monte Carlo 方法和电极调节策略，以预测电弧辐射散热并跟踪瞬时电极运动。在工业规模的 NLMK 150 吨电弧炉中设计并实施了电弧和相干喷射燃烧器熔炼废钢的实验，用于模型验证。将所提出的模型应用于模拟NLMK EAF典型运行下的废钢熔化过程，并根据模拟结果对废钢熔化行为、电弧性能和燃烧器性能进行了评估和讨论。分别开发了与 CFD 兼容的 Monte Carlo 方法和电极调节策略，以预测电弧辐射散热并跟踪瞬时电极运动。在工业规模的 NLMK 150 吨电弧炉中设计并实施了电弧和相干喷射燃烧器熔炼废钢的实验，用于模型验证。将所提出的模型应用于模拟NLMK EAF典型运行下的废钢熔化过程，并根据模拟结果对废钢熔化行为、电弧性能和燃烧器性能进行了评估和讨论。在工业规模的 NLMK 150 吨电弧炉中设计并实施了电弧和相干喷射燃烧器熔炼废钢的实验，用于模型验证。将所提出的模型应用于模拟NLMK EAF典型运行下的废钢熔化过程，并根据模拟结果对废钢熔化行为、电弧性能和燃烧器性能进行了评估和讨论。在工业规模的 NLMK 150 吨电弧炉中设计并实施了电弧和相干喷射燃烧器熔炼废钢的实验，用于模型验证。将所提出的模型应用于模拟NLMK EAF典型运行下的废钢熔化过程，并根据模拟结果对废钢熔化行为、电弧性能和燃烧器性能进行了评估和讨论。